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<p>As global economies increasingly embrace sustainable energy infrastructures, the demand for effective recycling approaches supporting the rapid expansion of lithium-ion batteries intensifies. Hydrometallurgy stands out among recycling routes for large-scale adoption, accommodating diverse cathode chemistries and facilitating precursor recovery for cathode resynthesis. However, there is a gap in understanding how the key material properties of resynthesized cathodes contribute to existing performance disparities, and the extent to which emerging hydrometallurgical closed-loop pathways can regenerate commercial-grade cathodes. This Review traces the evolution of spent cathodes through closed-loop hydrometallurgical pathways, benchmarking resynthesized cathodes against commercial analogues. We investigate and link observed performance deviations to precursor quality, originating from variable battery leachate composition. Key bottlenecks in recovering battery-grade precursors from complex leachates derived from traditional (mineral acid) and emerging sustainable hydrometallurgical routes (bioleaching, organic acids and deep eutectic solvents) are identified. These bottlenecks are directly linked to primary factors governing precursor quality such as impurity profiles, phase composition and microstructure. Practical insights to minimize the current performance gaps by bridging leachate chemistry and precursor architecture are discussed, providing guidance for the design of closed-loop hydrometallurgical recycling processes capable of functional cathode resynthesis.</p>

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Closed-loop battery recycling through cathode resynthesis

  • 期刊论文

  • 发表日期：

    2026年7月27日

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  • Yi Cai,
  • Ruirui Zhao,
  • Deepika Ranganathan,
  • Madhavi Srinivasan

摘要

As global economies increasingly embrace sustainable energy infrastructures, the demand for effective recycling approaches supporting the rapid expansion of lithium-ion batteries intensifies. Hydrometallurgy stands out among recycling routes for large-scale adoption, accommodating diverse cathode chemistries and facilitating precursor recovery for cathode resynthesis. However, there is a gap in understanding how the key material properties of resynthesized cathodes contribute to existing performance disparities, and the extent to which emerging hydrometallurgical closed-loop pathways can regenerate commercial-grade cathodes. This Review traces the evolution of spent cathodes through closed-loop hydrometallurgical pathways, benchmarking resynthesized cathodes against commercial analogues. We investigate and link observed performance deviations to precursor quality, originating from variable battery leachate composition. Key bottlenecks in recovering battery-grade precursors from complex leachates derived from traditional (mineral acid) and emerging sustainable hydrometallurgical routes (bioleaching, organic acids and deep eutectic solvents) are identified. These bottlenecks are directly linked to primary factors governing precursor quality such as impurity profiles, phase composition and microstructure. Practical insights to minimize the current performance gaps by bridging leachate chemistry and precursor architecture are discussed, providing guidance for the design of closed-loop hydrometallurgical recycling processes capable of functional cathode resynthesis.